Dual Wire Feed Motor Control for Bird-Nesting-Free Welding
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Solution Overview
Problem
Conventional welding wire feeding systems require empirical settings and constant calibration or specialized equipment to prevent bird-nesting and shaving, especially when feeding aluminum wire, which is challenging due to the high column strength of 5XXX alloys.
Innovation Solution
A push-pull wire feeding system with a push motor and a pull motor, where the push motor is a brushed DC motor coupled with a tachometer or current sensor, and control circuitry monitors the detected current and speed to maintain a fixed operating speed, controlling the torque of the pull motor and speed of the push motor to synchronize them without the need for empirical settings or specialty equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional wire feeding systems are used with multiple motors, then wire feed capability is improved, but the system requires empirical settings and constant calibration
Solution Approach 1:
The patent implements feedback control by monitoring the current drawn by the pull motor and using this information to adjust the push motor speed. The control circuit continuously monitors pull motor current and dynamically adjusts push motor operation to maintain synchronized wire feeding, eliminating the need for manual calibration and empirical settings while maintaining productive wire feed capability
2Productivity
If conventional wire feeding systems are used with multiple motors, then wire feed capability is improved, but specialized equipment is required to prevent bird-nesting and shaving
Solution Approach 1:
The system uses feedback from pull motor current monitoring to dynamically control push motor speed, preventing bird-nesting and shaving without requiring specialized equipment. The control circuit processes the current feedback signal and adjusts push motor operation in real-time, achieving reliable wire feeding with standard components
Solution Approach 2:
The system performs self-adjustment by using the pull motor's own current consumption as the feedback signal to control the push motor. This self-service mechanism automatically prevents feeding problems like bird-nesting and shaving without requiring external specialized equipment or manual intervention
3Reliability
If pull motor torque and push motor speed are controlled to synchronize, then wire feed consistency is improved, but control system complexity increases
Solution Approach 1:
The patent achieves reliable wire feed consistency through feedback control where the pull motor's current consumption serves as the control signal for the push motor. The control circuit monitors pull motor current and adjusts push motor speed accordingly, maintaining synchronized operation and consistent wire feeding without requiring complex multi-sensor control systems
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively feeds welding wire without bird-nesting or shaving, maintaining consistent wire feed by actively controlling the torque and speed of the motors, eliminating the need for calibration and specialized equipment, ensuring reliable operation across varying conditions.
Implementation Method 1
a sensor to provide a feedback signal indicative of a current through the pull motor
Implementation Method 2
the control circuitry converts the feedback signal into a control signal for the pull motor to control a torque of the pull motor
Implementation Method 3
controlling the torque of the pull motor and speed of the push motor to synchronize them
Data Source
AI summary
A system for controlling multiple wire feed motors for use in a welding-type system including a push motor controlled to operate at a target wire feed speed and a pull motor disposed in a welding torch controlled to apply a target torque to the fed welding wire. Such a system eliminates shaving and bird nesting of welding wire.